Garment strap material

ABSTRACT

AN IMPROVED GARMENT STRAP MATERIAL AND METHOD OF MAKING THE SAME, THE STRAP COMPRISING A DOUBLE THICKNESS OF MATERIAL. A WEB OF MATERIAL OF ESSENTIALLY TWICE THE WIDTH OF STRAP DESIRED IS FORMED OR FOLDED ALONG TWO FOLD LINES TO DISPOSE THE MARGINAL EDGES OF THE WEB IN ADJACENT OR ABUTTING RELATION ON ONE WURFACE OF THE STRAP MATERIAL. THE EDGES ARE THEREAFTER COVERED BY FLOCKING BONDED TO THE SURFACE, THE ADHESIVE, IN ADDITON TO ITS FLOCK SUPPORTING FUCTION, LAMINATING THE DOUBLE LAYERS OF MATERIAL.

July 13, 1971 c, v, Y, JR 3,592,719

GARMENT STRAP MATERIAL 7 Filed 061;. 25, 1968 FIG./

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INVEN'I'OR. CLAUDE V OFFRAY, Jr.

ATTORNEY United States Patent O 3,592,719 GARMENT STRAP MATERIAL ClaudeV. Otfray, .112, 21 Portland Road, Summit, NJ. 07901 Filed Oct. 25,1968, Ser. No. 770,649 Int. Cl. A41f /00 US. Cl. 161-64 1 Claim ABSTRACTOF THE DISCLOSURE BACKGROUND OF THE INVENTION Field of the inventionThis invention is in the field of straps for garments and relatesparticularly to an improved strap and method of making the same whichhas the appearance of a seamless strap, which is comfortable less,liable to slipping relative to the skin of the wearer, and resistant tocurling.

The prior art Herctofore many forms of garment straps have been employedin such applications as brassieres, slips and similar garments. Suchstraps typically have been comprised of knitted or woven materials ofeither single or double layer construction.

.It is also known to provide a rubber strap material, and to render thesame more comfortable to the wearer by applying a flock to one surfaceof the strap.

While a knitted, seamless, double layered strap material is preferred toother types, the cost of such material is considerably greater thanstraps formed by folding a web and stitching the two layers together.The stitchedtogether strap, while functionally the equivalent of theknitted, seamless strap, is considered to be less desirable since thestitching is unsightly and subject, after use, to unravelling. Theexposed selvage edges of the fabric are likely to become frayed and wornafter weakening of the stitching thus detracting from the apearance ofthe garment.

SUMMARY OF THE INVENTION An improved strap material formed of a web, themarginal edges of which have been inturned and bonded to the back layer,the edges being preferably brought into abutting relation substantiallycentrally of one surface of the strap. An adhesive is applied over theabutting edges and worked through the surface to unite the front andback faces of the web, the adhesive serving the additional function ofsupporting a flock which overlies the marginal edges, thus to concealthe seam. Preferably the flock extends for less than the entire width ofthe strap.

In use, with the flocked surface against the skin of the wearer, thestrap will assume a normally concave configuration due to the thicknessof the flock layer, with the flock at the inner face of the concavity,thereby to define a strap structure less likely to slip relative to theskin of the wearer and yet provide a high comfort factor.

The marginal edges of the folded strap provide the desirable roll edgeappearance associated with the more 3,592,719 Patented July 13, 1971expensive seamless knitted strap, and the free or selva-ge edges areentirely concealed and thus not subject to wear or unravelling.

The invention further relates to a method of making a strap of the typedescribed which includes the steps of inturning the marginal edges of asingle thickness web toward each other, applying an adhesive to thesurface which includes the inturned marginal edges, which adhesive isworked through the fabric in such manner as to secure the layers thusformed to each other, applying a flock to the still uncured adhesive andthereafter curing the adhesive simultaneously to connect the flock andlaminate the layers.

It is accordingly an object of the invention to provide an improvedstrap material. I

It is a further object of the invention to provide a strap material ofthe type described which is less expensive to manufacture than knittedseamless straps while possessing all of the advantages of appearanceinherent in such knitted straps.

It is a further object of the invention to provide a strap of the typedescribed having a central flocking strip concealing the two marginaledges of the web, the flocking preferably extending for less than theentire width of a surface of the strap to provide a strap which isconcave in use and, hence less likely to wander or slip relative to theskin of the wearer, while at the same time providing a high comfortfactor.

It is still a further object of the invention to provide a method ofmaking a strap of the type described.

To attain these objects and such further objects as may appear herein orbe hereinafter pointed out, reference is made to the accompanyingdrawings, forming a part hereof, in which:

'FIG. (1 is a schematic view of processing equipment for forming a strapmaterial of the type described;

FIG. 2 is a section through the web of material after completion of thefolding step;

FIG. 3 is a magnified sectional view through the material afterapplication of the adhesive;

FIG. 4 is a magnified sectional view after the flocking step;

FIG. 5 is a sectional View showing the position assumed by the partswhen the strap is stressed over the shoulder of a wearer.

Reference will now be made to the drawings forming a part hereof. Theimproved strap material may employ as a matrix or substrate, porouscloth material 10 such as broadcloth or like woven or knitted materialmade of nylon, rayon, etc. The material, which may be supplied indesired narrow widths of l or 1%" or which may be severed from a bulksupply to the desired width, is first fed through a folding station 11from a supply drum 12. The full width web or substrate is led through aseries of folding guides or rolls of any desired type which turn themarginal edges 13, .14 of the material inwardly essentially to the edgeabutting relation shown in FIG. 2.

For purposes of clarity, the minor body portions 15, 16 which comprisethe parts of the web lying between the end fold 17 and edge :13, and theend fold 18 and edge 14 respectively, are shown as spaced away from themajor or body portion or back 19 of the web although this space, inpractice, would not exist since the result of the folding step istightly to compress the minor body portion against the back portion.

The folded fabric is passed through an adhesive applying station 20,whereat a suitable adhesive material 21 is applied against the outersurfaces of the minor body portions 15, 16. A series of doctor blades orlike expedients within the adhesive station 20 force the adhesivethrough the interstices of the fabric so as to connect the minor bodyportions with the back portion 19.

As best seen from FIG. 3, the adhesive material 21 is not applied acrossthe entire width of the minor body portions 15, 16, the adhesive beingpreferably limited in its application to a central portion of theseparts, to leave the outer edge areas 22, 23 free of adhesive.

It will be understood that as a result of the adhesive applying step,and in addition to the quantity of adhesive which connects the minorbody portions to the back layer 19, there remains a tacky surface layerof adhesive covering the central part of the upper surface which isdefined by the minor body portions, the tacky outer adhesive componentsforming an anchoring medium for the flock which is applied at theflocking station 24.

The flock 25 may be applied either by electrostatic deposition or by abeater bar type of applicator, depending particularly on the nature ofthe finish which is desired. Where the flock fibers are desired to bedisposed essentially normal to the surface of the article, as shown inFIG. 4, electrostatic deposition is employed. Where random orientationof the flock fibers is satisfactory, beater bar application isaltogether feasible.

The flocked material shown in FIG. 4 is next led through a drying andcuring station 26 which may employ any known drying expedient, includinghigh frequency or conventional drying techniques to effect curing of theadhesive and consequent bonding of the flock to the adhesive coveredsurface portions of the minor body portions 15, 16.

The drying step likewise effects curing of the cement between the backlayer and the minor body portions, thus to laminate these parts.

The dried material is wound on a take-up roll 27, at which point thestrap material is ready for use.

It will be appreciated that as all of the individual steps, namely, thefolding, adhesive application, flocking and drying steps are well knownand may be carried out by a variety of available equipment, descriptionsthereof have been eliminated for purposes of simplicity.

Similarly, in the diagrammatic showing of FIG. 1, while the processinghas been indicated to be a continuous one in which the various steps arecarried out by a single apparatus which subjects the web to a subsequenttreatment directly after it has completed a previous treatment, it willbe appreciated that some of the steps may be carried out on anon-continuous basis and the intermediate product stored. Specifically,it is feasible to fold the material at a time and position remote fromthe ensuing processing steps, and thereafter complete the adhesiveapplication, flocking and drying.

While it will be evident to the skilled worker from the foregoingdescription that a variety of materials may be used, depending on thecharacteristics of the end product which is sought, there is illustratedbelow a suggested group of materials which have been found suitable forthe formation of strap materials for brassieres.

In accordance with the preferred embodiment and for purposes ofcompliance with the patent statutes, the web material 10 may comprise acotton broadcloth of about 60 count lengthwise and 100 count widthwise.

The flock retaining and laminating adhesive may comprise a latex type,water base emulsion, such as HYCAR (T.M.) 2679 or 2671 made by B. F.Goodrich. A further suitable adhesive, in this instance a selfcross-linking acrylic type, is emulsion 177B, manufactured by HauthawayCorp. of Lynn, Mass.

It will be readily understood that many suitable organic solvent basedadhesives will suggest themselves for use in the procedure.

The adhesives specifically set forth have a viscosity in the range ofabout 48,000 to 52,000 cps. at 75 R, which viscosity has been foundsuitable to achieve the desired spreading, as well as permittingpenetration of the cotton fabric having the count above set forth.

It will be readily recognized that variations in the viscosity and inthe quantity of adhesive should be made elO where fabrics of differentcomposition and/or count are to be employed. The amount of adhesiveapplied may best be determined by experiment with each different fabric,as is usual in laminating applications, it being preferred to usesufficient adhesive to provide a strong interlayer bond but to avoid theapplication of adhesives of such low viscosity or in such quantity as topermit the adhesive to show through the backing layer 19. In the processof applying the adhesive, sufficient flock retaining quantities must bepermitted to remain on the surface.

Various types of flocking materials have been found satisfactory and, asis well known, the nature and size of the flocculant chosen, as well asthe manner of its aplication, will cause considerable variation in theappearance and characteristics of the flocked effect.

With the use of the materials and adhesives set forth above, a varietyof flock types have been satisfactorily applied. By way of example,ground cotton flock of random length has been used. Also graded rayonflock 3 denier .03" length or 6 denier .06" length have been foundsatisfactory.

The use of nylon flock with the above materials has also beensatisfactorily tested and a 3 denier to 6 denier nylon flock in lengthvarying between .03" to .06 1s recommended.

The flock type, sizes and lengths are by no means limitative and othermaterials and size ranges will undoubtedly be found satisfactory,depending upon the particular application in which they are to beemployed.

Where electrostatic deposition of the flock is contemplated, the flockmust be AC and DC treated by the manufacturer, such treatment not beingnecessary for beater bar application.

As shown in FIG. 5, the flock material 25 covers a transverse area whichincludes the mating or end-abutting marginal edges 13, 14 of the webmaterial. Thus, no stitching or selvage edges are visible in thefinished material.

By reason of the application of the flock layer at a central portiononly of the strap, the strap, when tensioned into position over aportion of the anatomy of the wearer (represented in FIG. 5 by theletter W), will assume an essentially concave configuration, with theconcavity being directed toward the wearer. This characteristic of thestrap material is highly desirable in that the tendency of the strap toslip or to roll or double over on itself is essentially eliminated.

In contrast, when ordinary straps are tensioned against the body of thewearer, there is a considerable tendency for the strap to cup or assumea convex configuration wherein the marginal edges of the strap areraised to a position clear of the wearer, contact with the wearer beingmaintained only by a central portion of the strap. When a strap of thisconventional sort is subjected to lateral stresses of the kind normallyencountered as a result of movement of the wearer, the strap tends tocup further and double up, and to slide relative to the shoulder of thewearer. The cupping or folding action is undesirable since, in additionto encouraging sliding movement of the strap, it increases the effectivethickness of the strap, permitting the strap to show through outergarments, such as sweaters. Moreover, the cupping tendency is cumulativein that, after the strap has been forced to a convex position, thefolding tendency weakens the central portions of the strap andfacilitates folding along this same weakened line on subsequent wearingsof the garment.

From the foregoing it will be appreciated that the present inventionprovides a strap material having advantages by way of improvedappearance, stability and resistance to cupping or curling.

It will be further appreciated that there is described herein animproved method of manufacturing flocked material of the type set forth.

Having thus described the invention and illustrated its use, what isclaimed as new and is desired to be secured by Letters Patent is:

1. As a new article of manufacture, a strap material for supporting agarment or the like, said material having front and rear portions,comprising a porous fabric web, said front portion of said strap beingdefined by folded over portions of said web, with the marginal edges ofsaid web disposed in substantial abutting relation, a flocked centralstrip portion in registry with said abutting marginal edges andconcealing the same, said strip extending across less than the entireWidth of said strap, thus to define a strap which is thicker at thecentral portions than at the side edges, whereby when a length of saidstrap is draped under tension over a body portion of a wearer with saidfront face adjacent the body, said rear portion of said strap willassume a convex configuration.

References Cited ROBERT F. BURNETT, Primary Examiner L. M. CARLIN,Assistant Examiner US. Cl. X.R.

